How to Build a Custom Foil Board: Hybrid Carbon & Fiberglass Construction

Описание: Documenting the full construction of a custom hydrofoil board designed for Parawing and Foil Assist. Free plans: https://flukeskitesurfing.com/store/h...
This build focuses on a hybrid material approach, using traditional surfboard building techniques to meet the specific structural demands.
While the industry has moved toward full carbon, I opted for a hybrid fiberglass/carbon layup over a dual-stringer EPS core. This provides the structural rigidity needed.
Because we have dual cedar stringers, it helps solve the "stiffness" issue with a I beam. Most carbon boards are "stringerless," relying entirely on the skin.
The board is built on a recycled 2.8lb density EPS Geotechnical foam core. To manage the longitudinal flex and the torque from the foil mast, I’ve used dual cedar stringers that run the full length of the blank.

The choice to use a hybrid carbon and fiberglass layup was based on balancing stiffness and durability, cost and DIY friendly build:

Carbon Fiber: Strategically placed as structural patches over the foil tracks and the standing area. This reinforces the high-stress zones where the mast interacts with the board and creates I beam with use of stringers

Fiberglass: Used for the main laminate. It provides better impact resistance and vibration dampening compared to a full carbon skin, which can often feel too rigid in choppy conditions.

Dual Stringers: These act as the primary skeleton, allowing the foil tracks to be anchored directly into wood rather than just foam and resin.

[Technical Steps]

Blank Prep: Gluing the EPS core with dual cedar stringers.

Shaping: Hull contours designed for clean water release and touch-down recovery.

Track Installation: Routing and reinforcing the foil boxes into the stringer line.

The Layup: Hand-glassing with epoxy resin, focusing on the carbon-to-glass transitions.

Finishing: Final hot-coat, sanding, and weight check.

Build Index
0:00 Project Overview
1:51 Construction Process
2:30 Blank
4:00 Outline template
4:20 Shaping the EPS Blank
13:00 Track Box and foil track Install
15:22 Laminating
22:06 Resin filler coat
24:00 Leash Plug
25:30 Sanding
26:40 Finishing
28:30 Water test


DIY hydrofoil board construction, EPS and Epoxy board building, hybrid carbon fiberglass layup, cedar stringer foil board, parawing board design, foil assist board build, surfboard shaping process.